Vickers Overhaul Manual Directional Controlspub/@eaton/@hyd/docu… · A. Purpose Of Manual This...

45
I-3618-S Revised 11/1/86 Directional Controls Overhaul Manual Vickers ® Directional Controls

Transcript of Vickers Overhaul Manual Directional Controlspub/@eaton/@hyd/docu… · A. Purpose Of Manual This...

I-3618-SRevised 11/1/86

Directional Controls

Overhaul ManualVickers®

Directional Controls

2

3

Table of Contents

Section Page

I. Introduction 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Purpose of Manual 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. General Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

II. Description 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. General 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Basic Four-Way Sliding Spool Directional Valve Construction 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Two Stage Directional Valve Construction 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

III. Valve Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. General 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Spool Types - Main Stage Section 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Methods of Spool Control, Main Stage 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Main Stage Spool Position 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Optional Features (Main Stage) 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IV. Pilot Valve Section 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Spool Type - Pilot Valve Section 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Spool Positioning - Pilot Valve Section 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Methods of Control - Pilot Valve 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V. Internal Valve Functions 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. General 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Pilot Pressure 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Pilot Valve Drains 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Internal Check Valves 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VI. Installation 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Installation Drawings 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Fluids and Seals 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Piping and Tubing 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Hydraulic Fluid Recommendations 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Cleanliness 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F. Overload Protection 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VII.Service, Inspection & Maintenance 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Service Tools 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Inspection 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Adding Fluid to the System 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Adjustments 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Replacement Parts 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F. Product Life 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G. Troubleshooting 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VIII.Overhaul 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Unit Removal 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Disassembly 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Pilot Valve Removal 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Main Stage Disassembly 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Pilot Valve Disassembly 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F. Cleaning 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G. Inspection, Repair and Replacement 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H. Assembly 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IX. Internal Body Passages and Plug Locations 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

X. Start-up and Test 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Start-Up 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Test 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Section I – Introduction A. Purpose Of Manual This manual describes operational characteristics,maintenance requirements and overhaul information forVickers DG3S4, DG4S4, DG4V, DG18V, DG19S and DF5Sseries single stage and two stage directional valves. Theinformation contained herein pertains to the latest designseries as listed in Table 1.

B. General Information 1. Related Publications - Service parts information

and installation dimensions are not contained in thismanual. The parts catalogs and installation drawingslisted in Table 1 are available from your local sales orengineering office.

2. Model Codes - Variations within each basic modelseries are covered in the model code. Table 2 shows acomplete breakdown of the model codes covering theseunits. Service inquiries should always include the completemodel code number as stamped on the nameplate.

Table 1. Related Publications

Model Description 50 DesignDF3S4-16*ADF3S4-16*ADF3S4-16*CDF3S4-16*CDF3S4-16*DF3S4-16*DF5S4-16*A-W(3)DF5S4-16*A-*ACDF5S4-16*A-*DCDF5S4-16*A-HDF5S4-16*DF5S4-16*B-W(3)DF5S4-16*C-W(3)DF5S4-16*C-*ACDF5S4-16*C-*DCDF5S4-16*C-HDF5S4-16*C-*DF5S4-16*N-W(3)DF5S4-16*N-*ACDF5S4-16*N-*DCDF5S4-16*N-HDF5S4-16*N-*XDF5S4-16*AXDF5S4-16*CXDF5S4-16*N

I-3539-S

I-3539-S

I-3539-S

51 Design

I-3482-S

53/54 Design

I-3555-S

I-3561-S

I-3561-SI-3623-S

I-3622-SI-3623-SI-3623-S

I-3622-SI-3623-S

I-3622-S

I-3486-S

I-3482-S

I-3486-SI-3482-S

I-3482-S

Additional Drawing

I-3499-SI-3498-S

I-3499-SI-3498-S

I-3499-SI-3498-S

I-3501-S

Installation Drawing

517100

518100

DF3S4-16**/DF5S4-16**/XDF5S4-16** SERIES

5

Table 1. Related Publications (cont’d)

Model Description 10/11 DesignDG3S-H8-*ADG3S-H8-*CDG3S-H8-**DG3S-8-*ADG3S-8*CDG3S-8*DDG3S-8**DG3S4-04**DG3S4-06*ADG3S4-06*CDG3S4-06*DDG3S4-06*DG3S4-10*ADG3S4-10*CDG3S4-10*D

I-3437-SI-3438-SI-3436-SI-3438-S

20/21 Design 40 DesignI-3443-SI-3444-SI-3444-S

Installation Drawing

I-3549-S

DG3S-H8/DG3S-8/DG3S4-04**/DG3S4-06**/DG3S4-10** SERIES

51 Design

I-3553-SI-3452-SI-3457-SI-3452-SI-3455-SI-3454-SI-3456-S

53/54 Design

I-3563-SI-3626-SI-3569-S

516320

516300

516710

516800

517000

Model Description 10/11 DesignDG17S4-012DG17S4-012ADG17S4-01*C/NDG17S4-06A/C/NDG17S4-10A/C/NDG17S4-10A/C/NDG17/20V-3-*A*DG17/20V-3-*C*DG17/20V-3-*N*DG17S-8-*CDG17S-8-*N

50 DesignI-3546-SI-3546-SI-3546-SI-3567-SI-3568-S

I-3551-SI-3551-SI-3632-S

Installation Drawing514500514500514500514705514705

514381

514701514701

DG17S/DG17S8/DG17/20V-3 SERIES

53 Design

I-3564-S

40 Design

I-3872-S

Model Description 10/11 DesignDG18S-8-*ADG18S-8-*CDG18S-8-*DG18S2-012NDG18S2-012NDG18S4-01*ADG18S4-01*CDG18S4-01*CDG18S4-01*NDG18S4-01*NDG18S4-01*NDG18S4-06*ADG18S4-06*CDG18S4-06*DG18V3-A/B/C/F/N

50 Design

I-3588-SI-3588-S

I-3589-S

I-3442-S

Installation Drawing

516050

516650

516061

DG18S-8/DG18S2-**/DG18S4-**/DG18V-3 SERIES

52 Design

I-3554-S

I-3592-S

I-3554-SI-3587-SI-3587-SI-3587-S

40 Design

I-3616-S

51 Design

I-3590-S

I-3590-S

Model Description 50 DesignDG19S4-H06**DG19S4-06*CDG19S4-06**DG19S4-10**DG19S4-04DG19S8DG19S-H8DG19SS4-10

70 Design

I-3588-S

I-3537-S

Installation Drawing

517905

518005

517906

518005

DG19S4 SERIES

52 DesignI-3574-S

I-3574-SI-3574-S

6

Table 1. Related Pulications (cont’d)

Model Description 10 DesignDG4V-3-*A(P)/B(P)/CDG4V-3-*A(P)DG4V-3-*B(P)DG4V-3-*CDG4V-3-*F(P)DG4V-3-*NDG4V-3-*N

I-3529-S11 Design 12 Design

I-3529-S

Installation Drawing

DG4V SERIES

40 Design

517350(10-12 Design)

517351(-40 Design)

I-3629-SI-3630-SI-3630-SI-3619-S

I-3631-S

I-3861-SI-3862-SI-3863-SI-3864-SI-3865-S

Model Description 50 DesignDG4S2-012A-*ACDG4S2-012A-*DCDG4S2-012A-HDG4S2-012C-*ACDG4S2-012N-*ACDG4S2-012N-*DCDG4S2-012N-HDG4S2-01*A-W(3)DG4S2-01*N-W(3)DG4S4-01*A-*ACDG4S4-01*A-*DCDG4S4-01*A-HDG4S4-01*A-W(3)DG4S4-01*B-W(3)DG4S4-01*C-*ACDG4S4-01*C-*DCDG4S4-01*C-HDG4S4-01*C-W(3)DG4S4-01*N-*ACDG4S4-01*N-*DCDG4S4-01*N-HDG4S4-01*N-W(3)

I-3478-SI-3507-SI-3485-SI-3477-S

I-3557-S

I-3478-SI-3507-SI-3485-SI-3557-SI-3558-SI-3477-SI-3506-SI-3483-SI-3558-S

51 Design

I-3471-SI-3522-SI-3472-S

I-3559-S

I-3471-SI-3522-SI-3472-SI-3559-S

Installation Drawing

DG4S2/DG4S4 SERIES

517401

517410

517410

517410

517410

517401

517401

517401

7

517850

518000518100

518000

518100

518000

518100

Table 1. Related Publications (cont’d)

Model Description10/11

Design

DG5S-H8-*A/B/C/NDG5S-8-*A/B/C/NDG5S-8-*DDG5S4-H06*A-MDG5S4-H06*A-*ACDG5S4-H06*C-MDG5S4-H06*C-*ACDG5S4-H06*DDG5S4-H06*N-MDG5S4-H06*N-*ACDG5S4-04*A/B/C/NDG5S4-06*ADG5S4-06*A-MDG5S4-06*A-*ACDG5S4-06*A-*DCDG5S4-06*A-HDG5S4-06*CDG5S4-06*C-MDG5S4-06*C-*ACDG5S4-06*C-*DCDG5S4-06*C-HDG5S4-06*DDG5S4-06*D-*ACDG5S4-06*D-*DCDG5S4-06*D-HDG5S4-06*NDG5S4-06*N-MDG5S4-06*N-*AC/DCDG5S4-10*N-HDG5S4-10*ADG5S4-10*A-MDG5S4-10*A-W(3)DG5S4-10*A-*ACDG5S4-10*A-*DCDG5S4-10*A-HDG5S4-10*A-*DG5S4-10*B-MDG5S4-10*B-W(3)DG5S4-10*B-*DG5S4-10*CDG5S4-10*C-MDG5S4-10*C-W(3)DG5S4-10*C-*ACDG5S4-10*C-*DCDG5S4-10*C-HDG5S4-10*C-*DG5S4-10*DDG5S4-10*D-W(3)DG5S4-10*D-*ACDG5S4-10*D-*DCDG5S4-10*D-HDG5S4-10*D-*DG5S4-10*NDG5S4-10*N-M

I-3439-SI-3440-S

InstallationDrawing

DG5S-H8/DG5S-8/DG5S4-H06**/DG5S4-06**/DG5S4-10**/XDG5S4-06**/XDG5S4-10** SERIES

20/21Design

I-3445-SI-3869-SI-3873-S

40 Design

I-3548-S

50 Design

I-3492-S

I-3490-S

I-3493-S

I-3491-S

I-3496-S

I-3494-S

I-3497-S

I-3495-S

51 Design

I-3446-SI-3459-SI-3447-SI-3458-SI-3460-SI-3448-SI-3461-S

I-3468-S

I-3502-S

I-3469-SI-3473-SI-3473-SI-3473-S

I-3504-S

I-3470-SI-3474-SI-3474-S

I-3449-S

I-3513-S

I-3450-S

I-3509-S

I-3514-S

I-3451-S

53/54Design

I-3621-SI-3627-S

I-3624-SI-3621-SI-3627-SI-3624-S

I-3621-SI-3627-S

I-3624-S

I-3628-S

I-3625-S

I-3621-S

70 Design

I-3870-S

Addl.Drawing

I-3499-SI-3498-S

I-3499-SI-3498-S

I-3499-SI-3498-S

I-3499-SI-3498-S

I-3499-SI-3498-S

I-3499-SI-3498-S

I-3499-SI-3498-S

517930

517840

517850517920517850

517920

517850517920517810517900517850

517900

517900

517900

518000

518100

517850

8

Table 1. Related Publications (cont’d)

DG5S4-10*N-W(3)DG5S4-10*N-*ACDG5S4-10*N-*DCDG5S4-06*N-*HDG5S4-06*N-*XDG5S4-06*AXDG5S4-06*CXDG5S4-06*DXDG5S4-06*NXDG5S4-10*AXDG5S4-10*CXDG5S4-10*DXDG5S4-10*N

DG5S-H8/DG5S-8/DG5S4-H06**/DG5S4-06**/DG5S4-10**/XDG5S4-06**/XDG5S4-10** SERIES

Model Description10/11

DesignInstallationDrawing

20/21Design 40 Design 50 Design

51Design

53/54Design

70 Design

Addl.Drawing

I-3512-S

I-3502-SI-3473-SI-3504-SI-3474-SI-3513-SI-3509-SI-3514-SI-3512-S

I-3627-S

I-3624-S

I-3499-SI-3498-S

518000

517900

518000

I-3501-S

9

Spool Type - Main Stage Section0 - Open center1 - Open center, P-A2 - Closed center3 - P & B blocked in center4 - Tandem center, closed crossover6 - P blocked in center7 - P, A &B interconnected,

T blocked8 - Tandem center, open center

crossover9 - Open center over tapers31 - Closed center, P-A33 - P blocked, A & B bleed to tank

131

3 4 6 1413101 2

2

3

10

F3 Viton Seals(omit for standard models)

X - HazardousLocation Solenoid (omit if not required)

XM - Mining Applications(omit if not required)

Electrical AccessoriesL - Solenoid indicator lightsW - Wiring housing

Pilot Valve and/or Solenoid TypeM - DG4V-3 pilot valve and adapter

plate (omitted on DG5S-8 (DG5S-H8 models)

H - Oil immersed solenoidW - Nonserviceable core tube,

wet armature solenoids onlyW3 - Serviceable core tube, wet

armature solenoids only

Table 2. Model Code Breakdown

8

4 Electrical Plug Feature(omit if not required)PB - Insta-Plug Male/Female

ConnectionPA3 - 3 pinPA5 - 5 pin

24 Left Hand Assembly(single solenoids only)(Omit for standard right hand models)

Model Code

5 249 11 12 15 16 17 18 19 20 21 22 23

5 S - Monitor Switch Feature(omit if not required)

6 Model SeriesDGF - Directional control, manifold

or subplate mounting, flange

7 Control Type4 - Elect. solenoid5 - Pilot - elect. solenoid17 - Manual lever18 - Air pressure19 - Pilot - air pressure

8 SpoolS - Slide spool

(rated pressure 320 bar, 3000 psi)V - Sliding spool

(raged pressure 345 bar, 5000 psi)

21

9 Flow Direction4 - Four-way (omit for DG5S-8

& DG5S-H8 models)

14 Pilot Pressure Range(pressure centered “D” models only)A - 200-1000 psiB - 1000-2000 psi

(omit - 2000-3000 psi)

15 Valve TypeA - Spring offset (one solenoid)B - Spring centered (one solenoid)C - Spring centeredD - Pressure centeredF - Spring offset to “A” portN - No spring-detented

(omit on no-spring, “floating” models

X - Fast Response Model(omit on standard low shockmodels)

16

H - High flow(omit for standard models)

11

12 Series04 - 1/2” (12 to 25 USgpm rated flow)06 - 3/4” (45 USgpm rated flow)H06 - 3/4” (80 USgpm rated flow)10 - 11/4” (100 USgpm rated flow)16 - 2” (200 USgpm rated flow)

interface (10/20 design models)(ISO-4401-8 (NFPA-D06)

8 - 170 liters (45 USgpm rated flow)H8 - 265 liters (70 USgpm rated flow)

17 Spool Control Modification(omit if not required)1 - Stroke adjustment2 - Pilot choke adjustment3 - Pilot choke and stoke adjustment7 - Stroke adjustment -

cylinder “A” end only8 - Stroke adjustment -

cylinder “B” end only

E - External Pilot Drain(omit if not required)

18

T - Internal PIlot Drain(omit - external pilot drain)

19

20 Check Valve in Pressure Port(omit if not required)K - 0.35 bar (5 psi) cracking pressR - 3.45 bar (50 psi) cracking pressS - 5.20 bar (75 psi) cracking press

7

Coil Identification & Voltage Range (pilot valve)B -115/120 Vac 60 Hz & 110 Vac 50 Hz

(8 & H8 series only)D -230 Vac 60 Hz & 220/230 Vac 50 HzF -6 VdcG -12 VdcH -24 VdcM-450 Vac 50 Hz & 460 Vac 60 Hz

(omit on standard 115 Vac 60 Hz models)

22

Design10 - DG5S-8 models only20 - DG5S-H8 models only40 - 04 models & dg4v-3 pilot,

DG18V-3 pilot50/52 -standard models53 - Latest design, SAE straight

thread construction plug70 - DG5S4-10 & DG19S4-10 only

23

10

Section II – Description

A. General Directional valves are devices used to change the flowdirection of fluid within a hydraulic circuit. A valve isdesigned to control the direction of movement of a workcylinder or the direction of rotation of a fluid motor.

B. Basic Four-Way Sliding SpoolDirectional Valve Construction Vickers valve bodies have a precision machined bore inwhich a very close tolerance spool is suspended on a film ofhydraulic fluid. Spool lands and body cavities are designedto divide the bore openings into separate chambers. Ports inthe body lead into these chambers so that spool positiondetermines which ports are open or closed. See Figure 1. Oilflow is directed from one port to another within the body andout of a port to the work.

C. Two Stage Directional ValveConstruction Two stage directional valves are pilot pressure operated. Atwo stage valve is constructed by combining a pilot valveand a larger main stage valve into one assembly. The pilotvalve, usually a DG4S4-01, DG4V-3 or DG18V-3 is mountedon top of the main stage valve. The pilot valve controls spoolmovement within the main stage section. Pilot spoolmovement is normally, actuated by electrical solenoids.When a solenoid is energized (activated), the pilot spoolmoves and fluid is diverted to the main stage; thuscontrolling main stage spool movement, Figure 2 illustratesthe basic construction of a two stage, pilot operateddirectional valve.

Figure 1. Spool Type Four-Way Valve

A

Pressure to “B”“A” to Tank

B

A B

A B

TT P

Pressure to “A”“B” to Tank

TP

TP

Figure 2. Typical “DG5” Type Solenoid Controlled, Pilot Operated Valve

1. This pilot stagespool controls the

pilot pressure which

2. can be directed toeither end of the

main stage spool.

External PilotDrain Port Manual override to

shift pilot stagemechanically when

troubleshooting

Internal PilotDrain Port

11

Section III – Valve Operation

A. General Directional Valve operation is determined by four factors;spool type, spool positioning, method of control, and specialfeatures. Proper selection of the above factors establish andregulate desired flow paths through the internal ports of thevalve. The following information discusses those factors withrespect to valve operations.

B. Spool Types - Main Stage SectionOperation of spools are governed by their design as well asthe means of control. The most common designs are opencenter, closed center and tandem. During the followingdiscussion, basic spool design is related to valve portopenings, with the spool in center position. Port openingsare stated as: P - Pressure Port, A & B - Actuator Ports, andT - Tank or Reservoir Port. Refer to Figure 3.

1. Open Center Spools (0, 1, 9 and 11): Open centervalves are used in single operations where no other opera-tion is performed by the same source of power and wherecylinders do not have to be held by pressure. Open centerspools are also used to minimize shock in a system. Shockdevelops when a valve spool is shifted from one position toanother across center position. The smoothest possibleminimum shock condition is obtained when fluid underpressure is allowed to discharge to tank as the spool passescenter condition.

Open center with (A) or (B) ports blocked. A spool of thistype is generally used to operate a cylinder. When the spoolis centered, a cylinder port is blocked and the cylinder is heldin a definite position. In some circuits, flow from the tank portis piped into the pressure port of another valve. This allowsthe same source of power to operate two different cylinders.This type of arrangement may be used in a systemcontaining a number of operations. However, each operationmust be performed in a certain sequence, with only oneoperation taking place at any one time.

a. Type “0” spool is designed with ports (P), (B), (A),and (T) interconnected when the spool is in center position.These ports are momentarily interconnected during spoolcrossover when the pilot valve solenoid is activated. Thispermits smooth rapid cycle operation.

b. Type “1” spool is designed with ports (P), (A), and(T) interconnected. Port (B) is blocked in center position.

c. Type “9” spool is similar to type“0” spool except allports are partially open in center position.

d. Type “11” spool is a type “1” spool reversed in thebore. The type “11” spool interconnects (P), (B), and (T) incenter position with (A) blocked.

2. Closed Center Spools (2, 3, 6, 31 and 33 types):Closed center spools are used where two or more opera-tions are performed by a single pump or by an accumulator.Closed center valves prevent the loss of fluid from the pumpor accumulator when the spool crosses center. The “P” portis blocked as the spool crosses center.

a. Type “2” spool blocks ports (P), (A), (B) and (T)from one another in the center position. The ports aremomentarily blocked during spool crossover.

b. Type “3” spool is designed with ports (A) and (T)interconnected and ports (P) and (B) blocked in the centerposition.

c. Type “6” spool is interconnected at ports (A), (B)and (T). Port (P) is blocked in the center position.

d. Type “31” spool is a type “3” spool reversed in thebore. A type “31” spool is interconnected at ports (B) and (T),but blocked at ports (P) and (A) in the center position.

e. Type “33” spool provides controlled leakage from port(A) and (B) to port (T). Port (P) is blocked in the center position.

3. Tandem Spools (4 and 8 types): Tandem spoolvalves are used in hydraulic circuits where two or morehydraulic cylinders or motors are controlled from a singlesource of power. The valve’s spool is designed so that incenter position, all cylinder connections are blocked and fullpump delivery is connected to tank. The tank connection ofone valve may be connected to the pressure connection ofanother valve and both valves operated simultaneously aslong as another valve and both valves operated simulta-neously as long as the combined pressures developed bythe two loads are within the capabilities of the power source.

a. Type “4” spool allows oil to circulate freely from port(P) to port (T) in the center position. Ports (A) and (B) areblocked to the work load.

b. Type “8” spool is designed similar to type “4” spool.Port (P) and (T) are interconnected in the center position.However, ports (A) and (B) are momentarily open duringspool crossover.

Open Center

“B” Closed - Pressure Open to Tank Thru “A”

Closed Center - All Ports Closed

A

P T

B

Type0

A

P T

B

Type1

A

P T

B

Type2

12

Pressure and “B” Closed - “A” Open to Tank

Closed Crossover, Pressure to “T” with“A” & “B” Blocked

Pressure Closed - “A” & “B” Open to Tank

A

P T

B

Type3

A

P T

B

Type4

A

P T

B

Type8

Tandem, Open Crossover, Pressure to “T”with “A” & “B” Blocked

Type6

A

P T

B

Open Center, Partial - All Ports

“A” Closed - Pressure Open to Tank thru “B”

Pressure and “A” Closed - “B” Open to Tank

A

P T

B

Type9

A

P T

B

Type11

A

P T

B

Type33

Closed Center - Bleed “A” & “B”

Type31

A

P T

B

A PT B

A PT B

A PT B

A PT B

A PT B

A PT B

A PT B

A PT B

C. Methods of Spool Control, MainStage

1. Manual Lever (all sizes except the DF*S4-16*size): A manual lever arrangement is available for shiftingcertain valves. The lever arrangement is connected to aspecial valve end cover. A spool with an extension protrudesthrough the cover and is acted upon by the lever. This allowsmanual positioning of the spool within the body. Large valvesrequire considerable force to move the spool when it isunder pressure. For this reason, the two inch valve size isnot available with a manual lever control. Examples of valveswith the manual lever control are: DG17S4-06*A-50,DG17S4-10*A-50, DG17S4-06*C-50, DG17V-3-*-40.

2. Remote Pilot Source: Main stage valves are avail-able for use with a remote source. This means that the valveis shifted from a remote pressure source by other valves inthe logic circuit. Examples of valves that use a remotepressure source are: DG3S4-06*C-50, DG3S4-10*C-50 andDG3S4-06*-50.

3. Integral Pilot Valve: The integral pilot type two stagevalve is a very common valve used in the field today. Twostage valves allow large volumes of fluid to be switched toand from an actuator with minimum power required forcontrol. Reference Figures 4 through 8, shown in the follow-ing section.

D. Main Stage Spool Position Main stage spools are positioned within the valve by specialarrangements. The four basic main stage spool positioningarrangements are: no spring-floating, spring centered, springoffset and pressure centered.

13

The following paragraphs (1 through 4) describe thesearrangements. A fifth function can be obtained by the use of adetent pilot valve. This function is discussed in paragraph five.

1. No Spring-Floating: When centering springs areomitted from the main stage spool, the spool is said to befloating. If control pressure is removed, a floating spoolcan move from its last position under the influence ofgravity or tank line pressure. This must be consideredduring the design of the system. Units with floating typespools have the model code letter omitted. (Example:DG3S4/DG4S4-062-**-51) Figure 4 illustrates floating spoolpositioning in a two-stage valve.

2. Spring Centered: A spring and washer arrangement isused on both ends of the main stage spool in the springcentered configuration. If control pressure is removed from aspring centered spool, the valve will go the center position dueto spring force. Two configurations of a two-stage springcentered valve can be obtained, a type “B” and a type “C”. Ifone solenoid is used on a spring centered pilot valve, themodel code is identified with the letter “B”. When two solenoidsare used, the model code is identified with the letter “C”. Figure5 illustrates spool positioning of a two-stage spring centered“C” model (i.e. DG5S4-062C-**-51).

Figure 4. No Springs, Floating Model

A

P

T

B

1. Solenoid “A” is energized and shifts pilot spool to theright. This opens pressureto pilot port “A” and the main stage spool.

2. When solenoid “A” is energized, the main stage spool will shift left. Flow from P-A and B-T is obtained.

3. Main stage spool will stay in this position until solenoid “B”is energized, but, may float toother positions with bothsolenoids de-energized.

A P B T

AB

1. Solenoids are de-energized.Pilot spool is in center positiondue to spring force.

Main Stage Spring

Figure 5. Spring Centered “C” Model

A

P

B

Main StageWasher

2. Main stage springs and washers keep main stagespool at center position.Flow is A & B - T with P-blocked. When solenoid “A” is energized, the pilotspool will shift to the right causing the main stage spoolto shift left. Flow would then be P-A and B-T.

T A P B T

AB

#6

14

3. Spring Offset: Single stage spring offset models useone spring to return the spool to an offset position. In two-stage models, the spring and washer is removed from themain stage and offset action is obtained from the pilot valve.Offset pilots have a solenoid removed from the spring end ofthe valve. Spring offset pilots control the main stage when thesolenoid is de-energized, through spring action, so long aspilot pressure is available. Spring offset valves have the letter“A” stamped into the nameplate (i.e. DG5S4-062A-**-51).Figure 6 illustrates an offset two-stage valve.

4. Pressure Centered: Pressure centered valvesprovide a more positive centering arrangement than normalspring centered valves. This is a accomplished in the follow-ing manner:

Assume both pilot valve solenoids are de-energized and themain stage spool is positioned to the left (see Figure 7). Pilotpressure is applied to both ends of the main stage from thenumber seven (7) pilot spool. The sleeve moves to the rightunder the influence of the spring and pilot pressure until thepiston shoulder is contacted. Since the sleeve and pistonareas are greater than the total spool area at the right handend of the valve, the sleeve continues to move to the rightcarrying the piston with it until it contacts the valve body(center position).

Assume the main stage spool was positioned to the rightwith both pilot valve solenoids de-energized, pilot pressure isapplied to the sleeve and piston areas on the left side but thesleeve is bottomed against the valve body at this time. Onlythe piston area applies force to the left end of the spool.Since the spool land area at the right side is greater than thepiston area, the spool will be forced to the left until the pistonshoulder butts against the sleeve (center position).

If pilot pressure falls below 150 psig, the centering springswill cause the spool to center within the valve body.

Pressure centered valves are not available with integralcheck valves. (Refer to Section V, Internal Valve Functions,for integral check valve information.) Pressure centeredmodels have the letter “D” stamped into the unit nameplate(i.e. DG5S4-062D-**-51). Figure 7 illustrates spool/springarrangement on pressure centered models.

NOTE

A fifth condition of the main stage spool can beobtained through use of a detent pilot stage. Referto the following paragraph.

5. Detent Valve Operation: Detent valve operation canbe achieved by installing a detent into the pilot valve. Adetent is assembled on one or both ends of the pilot spooldepending on the type of pilot valve used. When a pilot valvesolenoid is de-energized, the detent holds the pilot spoolinits last position attained and the main stage spool remains inits last position.

CAUTION

If pilot pressure fails or falls below the minimumrequirement of 75 PSIG, the main stage spool willshift to center position even though the pilot valveremains in the last detent position. For this reason,flow conditions in center or neutral position must beselected with care.

Detent models are indicated by the letter “N” stamped intothe unit nameplate (i.e. DG5S4-062N-**-51). Figure 8illustrates the spool/spring arrangement on detent models.

Solenoid isde-energized

Figure 6. Spring Offset “A” Model

P

B

Main StageT A P B T

AB

The spring returns pilotspool to “A” offset positionand shifts main stagespool. Main stage oil flowis P-A and B-T.

15

Shoulderof Piston

Figure 7. Pressure Centered “D” Model

P

B

Piston

T A P B T

AB

1. Solenoids are de-energized.Pilot spool is in center position.(P-A & B, T blocked) (shown).

2. Pilot pressure keeps main stage spool in center position. Flow is blocked to all ports.

3. When solenoid “B” is energized,the pilot spool shifts to the left. Oil under pressure enters pistonarea causing the main stage spool to shift to the right. Main stage flow from P-B and A-T is obtained.

A

SleeveTank

Detent

Figure 8. Detented “N” Model

Main Stage

1. Solenoid “A” is energized andshifts pilot spool to right.

2. Which causes main stage spool to shift left. Oil flow is P-A and B-T.

3. Main stage spool remains in position attained due to pilot valve detent until solenoid “B” is energized. (NOTE: If pilot pressure fails, the main stage spool will shift to center position.)

Pilot Solenoid

PB

T A P B T

AB

A

16

E. Optional Features (Main Stage) Control of the main stage spool can be modified with certainoptional features. The most common features are discussedin the following paragraphs.

1. Stroke Limiter Adjustment: Main stage spool travelcan be limited by using stoke adjust covers. Stroke adjustcovers may be used on one or both ends of the main stagesection. When the stoke is limited, maximum flow throughthe valve is reduced (assuming the same inlet pressure).This slows the actuator movement.

To limit the spool travel, loosen the jam nut and turnadjusting screw clockwise. Figures 9 and 10c illustrate thestoke limiter feature.

2. Pilot Choke Option: A pilot choke increases theamount of time it takes to shift the main stage spool fromone position to another. Increasing shift time lowers thepossibility of developing large flow transients in the circuit. Apilot choke is designed to allow free flow to one end of themain stage spool but restricts flow out of the opposite end.The rate of spool travel, in either direction, can be slowed byloosening a locknut and turning an adjusting screw

clockwise. To increase the rate of spool travel, turn theadjusting screws counterclockwise. When a pilot choke isused, pilot pressure should be taken from a constantpressure source. The pilot choke is mounted between thepilot valve and the main stage sections. See Figures 10a,10b and 10c for pilot choke details.

3. Fast Response Option: Some applications requirethe main stage spool to shift at a faster than normal rate. Forsuch applications, the fast response option is used. Thisoption requires the removal of an orifice plug within the mainstage body. When the orifice plug is removed, largervolumes of fluid will enter the pilot valve section. When thepilot valve shifts, the main stage spool responds at a fasterrate. However, this also generates transients that increasesystem shock. For this reason, the fast response option isnot recommended when pilot pressures exceed 140 bar(2000 psi). Fast response models have the letter “X”stamped into the unit nameplate (i.e. DG5S4-062**X-51).Table 3 compares standard shift times to the fast responseoption. Figure 23a and b through 27a and b show thelocation of the orifice plugs that must be removed for the fastresponse option.

Typical Shift Times in Seconds for AC Models

Table 3. DG5 Shift Times (AC Solenoids)

Pilot Pressure (psi)

Standard Fast Response

Center to “A” or “B” Center to “A” or “B”

Model 06 Model H06 Model 100 Model 06 Model H06 Model 100

500 .100 .130 .135 .045 .070 .0901000 .060 .085 .090 .035 .060 .0602000 .050 .070 .070 .035 .060 .0503000 .050 .070 .055 .035 .060 .050

All spring centered models require approximately .08 (06), .15 (H06), .19 (100) of a second to center from either side.

DC solenoid shift times will be approximately three or four times the above AC values.

Part No. Part Name1 Cover2 Spring3 O-Ring4 Washer5 Piston6 O-Ring7 Jam Nut8 Adj. Screw

Figure 9. Part Tab

Figure 9. Stoke Adjuster Feature

MainStageSpool 5

6

7

8

43 2

1

17

Part No. Part Name Qty.1 Screw 22 Nut 23 Needle Housing 24 O-Ring 25 Needle 26 O-Ring 27 Spring 28 Poppet 29 Body 110 O-Ring 411 Roll Pin 1

Figure 10a. Part Tab

Figure 10a. Pilot Choke - DGFN-01-20 (Use with DG4S4-01 Series)

DGMFN-3-21

5

67

8

11

3

2

1

10

4

9

Part No. Part Name Qty.1 Retaining Ring 22 Plug 23 O-Ring 24 Spring 25 Check Valve 26 Stop 27 O-Ring 28 Lock Nut 29 Adj. Screw 210 Plug 211 Body 112 O-Ring 5

Figure 10b. Part Tab

Figure 10b. Pilot Choke - DGFN-01-20 (Use with DG4S4-01 Series)

DGFN-01-20

7

8

4 3

2

1

1110

56

9

12

18

Stroke adjustmentslimit maximumspool travel.

Figure 10c. DG5S4 with Pilot Choke & Stroke LImiter Options

Main StageSpool

Adjustments to restrictpilot exhaust flow.

Free flow through thischeck valve when pilotpressure is directed in.

Adjustable orifice restrictspilot exhaust flow to slowmain stage spools shift.

Pilot Stage Spool

Pilot Choke Block

Section IV – Pilot Valve Section

A. Spool Type - Pilot Valve Section To maintain proper control, closed center pilot spools arenormally used on two stage valves. In most cases, a number“6“ type pilot spool is used.

When a type “4” or “8” main stage spool is used, the number“6” pilot spool is identified as number “68”. This spool com-bination requires the pilot valve to be assembled left hand onsingle solenoid models. Refer to installation drawing (Table1) for more information.

The number “7” pilot spool is identified as a number “78”when a “4” or “8” type main stage spool is used on pressurecentered “D” models.

B. Spool Positioning - PIlot ValveSection Pilot spools are positioned within the valve by special spoolarrangements. The three basic pilot valve spool arrange-ments are spring centered, spring offset and detents. Thefollowing paragraphs (1 through 3) describe pilot spoolarrangements.

19

1. Spring Centered: A spring and washer are installedat each end of the pilot valve spool. The spring moves thespool until the washer contacts the end of the valve body. Inthe de-energized condition of the pilot valve, the spool isheld in center position within the body by the springs andwashers.

2. Spring Offset: Spring offset models use one springand washer to return the pilot valve spool to an offset posi-tion. In this model, a solenoid is completely removed fromthe spring end of the pilot valve. Solenoid operating power isreduced by the sacrifice of the center spool position.

3. Detents: A detent mechanism is installed on one orboth ends of the pilot valve spool. Detent valve solenoidscan be momentarily energized to the correct position andthen power may be removed from the solenoid. This reducesthe input control power below that of an offset model. Thedetent(s) hold the pilot spool in the last position attained untilthe opposite solenoid is energized. As in the offset valve,solenoid power is reduced by the sacrifice of the centerspool position.

C. Methods of Control - Pilot Valve The following pilot control methods are available for pilot andspool position.

Manual Lever/RollerRemote PilotAir Type Solenoid

DG17/20V-3DG3V-3

DG18V-3, DG18S4-01DG4S4-01, DG4S4-01-W, W,

DG4V-3

Control Model Codes

Electrical Solenoid

1. Manual Lever/Roller: A manual lever is available forshifting certain valves. The lever arrangement is connectedto a special valve end cover. A spool with an extensionprotrudes through the cover and is acted upon by the lever.This allows manual positioning of the pilot valve spool withinthe body. In some valves a roller is used instead of a lever toactuate the pilot spool.

2. Remote Pilot: Pilot valves, such as a DG3V-3-*40,are available for use with a remote pilot source. This meansthat a valve can be shifted from a remote pressure source byother valves in the logic circuit. Refer to service parts draw-ing I-3871-S.

3. Air Type Solenoids: Air operated pilot valves areactuated with air pressure through a connection plate.

A DG18V-3-C-40 or DG18S-01-L-52 air type valve can beused to control the main stage of a DG19S4-062C-**-51 twostage unit (see Figure 11a). When air pressure (50 psi mini-mum) enters the pilot valve air chamber, the piston movesthe pilot spool. This allows control flow to enter the mainstage section (see Figure 11b).

Pilot Stage Valve DG18S4Directional Valve

AirConnection

#1

Pilot Choke(When Req’d)

DG19S4-06**-*-52DG19S4-H06**-*-52DG19S4-10**-*-52

AirConnection

Plate

DG3S4 Main Stage Valve

AirConnection

#2

11a. DG19S4-**-52 Two Stage Valve

The DG18S4-06 and DG18S-8 air operated valves do notuse a pilot stage but are shifted directly by large air pistonslocated at each end of the spool. The air pistons operatesimilarly to those of the DG18S4-01* pilot shown in Figure11b. A connection plate is required to feed air to the pistons.

4. Electrical Solenoid Pilot Operation: Electricalsolenoids are attached to the pilot valve body. Internal pushpins connect the solenoid to the pilot spool. When themagnetic field of solenoid “B” is energized, the solenoidarmature moves the push pin and shifts the pilot spooltowards solenoid “A” (see Figure 12a). When solenoid “A” isenergized, the pilot spool shifts toward solenoid “B” (seeFigure 12b). When both solenoids are de-energized, the pilotspool shifts to center position (see Figure 12c).

20

Figure 11b. DG18S4-**-52 Air Operated Pilot Valve

Air pressure is appliedto piston area and shift pilot spool.Oil under pressure enters main stage section and shiftsmain stage spool.

PIston PIston

Air Connection #2

Connection Plate

Control Flow toMain Stage Control Flow to Tank

from Main Stage

Air Connection #1

A B

CAUTION

DO NOT energize both (AC) solenoids simulta-neously. Sustained operation with both solenoidsenergized will cause excessive current in the coiland accelerates burnout.

a. Electrical Solenoid Types Available: Threebasic types of electrical solenoids exist: Wet armature, airgap and oil immersed. The unit nameplate identifies the typeof solenoid being used. See the model code in Table 2. If a50 or 51 design two stage valve is equipped with a DG4V-3pilot valve, the letter “M” is stamped into the nameplate (i.e.DG5S4-062*-*M-51). The letter “M” indicates an adapterplate is used to provide the necessary DG4V-3 pilot valveinterface requirements.

b. Wet Armature Type Solenoids: Wet armaturesolenoids are standard on DG4V-3 and DG4S4-01-W/W3pilot valves only. Wet armature solenoids have many designadvantages over other types of solenoids. Some advantagesinclude cooler operation, static sealing arrangements,immunity to moisture and greater burn-out resistance.

DG4V-3 and DG4S4-01*-W wet armature solenoids are notserviced with individual parts. Service is provided byreplacing the entire core tube subassembly. Parts can beremoved, cleaned and seals replaced on “W3” typesolenoids.

c. Air Gap Solenoids: DG4S4-01 pilot valves areusually equipped with air gap solenoids. Air gap solenoidsare isolated from system fluid and can be removed andreplaced without disturbing the system. A push pin andsliding seal arrangement couple the solenoid to the valvespool (see Figure 13c).

d. Oil Immersed Solenoids (early type wetarmature solenoid - no longer recommended for newequipment): DG4S4-01 pilot valves may be equipped with oilimmersed solenoids. This solenoid provides a certainamount of dampening of the solenoid parts and extends unitlife. The standard wet armature solenoid provides this samefeature. Oil immersed solenoids are not repairable except bythe manufacturer and are not directly interchangeable withair gap or wet armature type valves. Oil immersed typesolenoids have the letter “H” stamped into the nameplate.

Open Center

12a. Flow Conditions Pressure to “B” - “A” to Tank

APT B

Solenoid “A” De-energizedSolenoid “B” De-energized

T

Solenoid “A” De-energized

APT B T

APT B T

Solenoid “B” De-energized

Solenoid “A” De-energizedSolenoid “B” De-energized

12b. Flow Conditions Pressure to “A” - “B” to Tank

12c. Flow Conditions Blocked (Center Condition #2 Spool)

e. Electrical Solenoid Voltage Requirement:Electrical solenoids are available in various AC and DCvoltage ranges. The standard voltage and frequency range is115 VAC, 60 Hz. Refer to parts and service drawings forunits with non-standard voltage ranges. Fifty (-50) andfifty-one (-51) design units have the voltage and frequencyrange stamped into the nameplate if other than standard.Ten (-10), twenty (-20) and fifty-three (-53) design units usean identification letter for the coil voltage and frequency.

f. Electrical Solenoid Ground Connections andWiring Housing: An electrical wiring housing with a 1/2 inchNPTF thread connection is available on DG4V-3 andDG4S4-01 pilot valves. The wiring housing can be rotated

21

180� from the position shown in Figure 13a. Wire groundingscrews are provided for convenience.

g. Manual Override: Each solenoid (electrical or airtype) has a manual override plunger to shift the pilot spool.This feature allows a technician to shift the pilot spool whenelectricity or air pressure is not available. Refer to Figures13a, 13b or 13c. To operate the manual override feature,obtain a small rod and push in on the plunger.

5. Accessories for Electrical Type Solenoids: Themodel code (Table 2) indicates the type of accessories usedon directional valves. Obtain a parts and service drawing foryour particular model (see Table 1). Most accessoriespertain to the pilot section. The most common types ofaccessories are discussed in the following paragraphs (athrough f).

a. Hazardous Location Solenoids: This type ofsolenoid is used at locations where added protection fromelectrical shortage failure is manditory. The solenoid housingis designed to completely enclose all wiring connections tothe valve. Hazardous location valves are underwritersapproved Class 1, Group D or Class 2, Group E-F-G, for 115and 230 volts, 60 Hz service.

Valves for mining applications are built to the Bureau ofMines schedule 2G-File X/P 837-2 and are available in allstandard voltages. Refer to parts drawing (Table 1) forfurther information.

b. Monitor (Limit) Switch Feature: The monitorswitch feature can be incorporated into a basic spring offsetdirectional valve. The switch monitors valve spool positionand can be wired into control circuits. This permits electricalinterlocking of various hydraulic controlled motions withoutresorting to external mechanical arrangements. The monitorswitch is a single pole, double throw contact arrangementwith “A”- normally closed and “B”- normally open. Switchratings are noted on installation drawing (Table 1). Themonitor switch housing does not provide a manual plungerfor operation of the switch or valve.

c. Insta-Plug Connectors: Pilot valves can besupplied with electrical connectors called insta-plugs. Theseconnectors allow quick disconnect of electrical power from thevalve. The following data pertains to the insta-plug feature:

PA - A prefix of PA in the model code indicatesthe male plug section of the insta-plug feature is includedon the valve.

PB - A prefix of PB in the model code indicatesboth the male plug and female receptacle are included withthe valve. The insta-plug feature is available on both theDG4V-3 and DG4S4-01 series directional valve.

WIRING NOTE

Connect white wires to “A” solenoid and black wiresto the “B” solenoid. Refer to parts drawing (Table 1)for additional data.

d. Brad Harrison Connectors: Brad Harrisonconnectors thread into the 1/2 NPTF opening in the wiringhousing of a DG4V-3 or a DG4S4-01 directional valve.

PA3 - A prefix of PA3 in the model code indicatesthe three pin male connector is included with the valve.

PA5 - A prefix of PA5 in the model code indicatesthe five pin male connector is included with the valve.

Female Brad Harrison connectors are notavailable from Vickers and must be supplied by the customer.

e. Solenoid Indicator Lights: Solenoid indicatorlights are available for installation on both the DG4V-3 andDG4S4-01 series directional valves. Indicator lights areconnected across the solenoids and will light when voltage ispresent at the solenoid. This gives an indication to thetechnician which solenoid is energized and aids introubleshooting a system. Refer to the appropriate partsdrawing for additional information.

22

Figure 13c. DG4S4-01-50 Pilot Valve, Sectional View

1/2 (NTPF) ThreadConnection

Manual Override Plunger

Wet Armature (Standard)

Push Pin

Terminal Box

BodyEnd Cover (“A” “B”,

or “F” Models)

Manual OverridePlunger

Wet Armature Solenoid

Pilot SpoolSolenoid Coil

Core Tube“C” Models

Solenoid “A” Missing

Figure 13b. DG4S4-W-50 Pilot Valve, Sectional View

Figure 13a. DG4V-3-40 Pilot Valve, Sectional View

“C” Models

“B” Models

Solenoid “A”Solenoid “B”

Manual OverridePlunger

Pilot Spool

23

Section V – Internal Valve Functions

A. General To insure the proper application of a two stage valve, pilotpressure, pilot drain and integral check valve options mustbe considered. The following paragraphs (B through D)discuss these options.

B. Pilot Pressure 1. Internal Pilot Pressure (Standard): Internal pilot

pressure can be obtained in two ways and must betailored for the application. Models with closed center typespools automatically provide internal pilot pressure.Models that use open center type spools require a checkvalve in the pressure (P) port to maintain minimum pilotpressure. In most cases, maximum internal pilot pressureis rated to 210 bar maximum (3000 psi). Minimum pilotpressure ratings are noted in the installation drawings(see Table 1).

2. External Pilot Pressure: When pilot pressure from aseparate source is used, it must be connected to the “X” port(external pilot pressure connection). Models that use exter-nal pilot pressure do not require a check valve at the pres-sure port. External pilot pressure models are identified withthe letter “E” stamped into the unit nameplate (i.e.DG5S4-062***E-51). Maximum external pilot pressure isalso rated at 210 bar (3000 psi).

3. Pilot Pressure Conversions: If it is necessary toconvert your unit from external pilot pressure to internal pilotpressure or vice versa, internal plug(s) must be removed oradded to the main stage body. See the figures noted in Table8 for internal plug locations.

4. Pressure Centered “D” Models (H06 & -10Series only): A pre-set pilot pressure can be obtained inthese models. Refer to the model code in Table 2 forpressure settings. Pilot pressure can be increased ordecreased by simply changing internal plugs in the mainstage body. Refer to plug table in parts drawing for partnumbers and see the figure noted in Table 8 for internalplug locations.

C. Pilot Valve Drains 1. Internal Drain: Internal drain models are used when

pressure surges in the tank line are small and CAN NOTovercome pilot pressure.

To shift a pilot spool, pilot pressure must always exceed tankpressure by a minimum amount. Figure 14 is an exampleshowing pilot pressure vs. tank pressure. Refer to the unitinstallation drawing for minimum pressure ratings. Internalpilot drain models have the letter “T” stamped on the unitnameplate (i.e. DG5S4-062-**t-51).

NOTE

A 150 psig ∆P must always be maintained toshift closed center pilot spools. A 75 psig ∆Pmust always be maintained to shift open centerpilot spools.

PIlot Pressure (1000 psig)

This tank line pressure subtractsform the applied pilot pressure.

Figure 14. Pilot Valve - Internal Drain

1000

900

800

700

600

500

400

300

200

100

0

NOTE

Tank Line Pressure Surge (850 psig)

Tank Line Pressure (750 psig)150psig∆P

2. External Drain (Standard): External drain models arerecommended if pressure surges in the tank line CAN over-come pilot pressure. Drain connection “Y” is used for external-ly drained models. Pressure centered “D” models use twodrain connections “Y” and “W”. All external drain connectionsMUST be piped directly to tank through surge free lines. Referto the installation drawing (Table 1) for further information.

3. Drain Conversions: If it is necessary to convert yourunit from external drain to internal drain or vice versa, aninternal “T” plug must be added or removed to the main bodysection. Figures 23c, 24c, 25c, 26c, and 27c show internal“T” plug locations on various models.

D. Integral Check Valves Check valves are located within the pressure port of themain stage section. The purpose of the check valve is todevelop back pressure, at the pressure port, when opencenter or tandem main stage spools are used. Backpressure is necessary to maintain internal pilot pressurewhen the main stage spool shifts to open center position.Table 4 indicates when an integral check valve is required.

Pilot PressureSource

Yes 0, 1, 4, 8, 9, 11No 2, 3, 6, 31, 33

External No All Spools

Table 4. Integral Check Valve Circuit Requirements

Integral CheckValve Req’d

Main StageSpool Type

Internal

Integral check valves are applicable at various cracking pres-sure ranges. Refer to the model code in Table 2 for checkvalve pressure ranges. The unit nameplate identifies whichcheck valve is used (i.e. DG5S4-062-***K*-51). Refer to instal-lation drawing (Table 1) for additional check valve information.

NOTE

As an alternate to the integral check valve, a 50/75psi check valve can be installed in the tank line ofthe valve to obtain pilot pressure.

24

Section VI – Installation

A. Installation Drawings The installation drawings listed in Table 1 show installationdimensions, port locations and operating parameters. Man-ifold, subplate and bolt kit information is also included.

NOTE

Detent valves must be installed with the valve spoolin the horizontal position for good machinereliability. The mounting position of spring offset andspring centered models is unrestricted.

NOTE

Make sure the “Y” drain port is piped directly to thetank. Back pressure cannot be tolerated at thisvalve port.

CAUTION

On solenoid operated directional valves make surean electrical ground is connected to the valve. Thisprevents the possibility of a shock hazard if a coildevelops a short circuit to the frame.

B. Fluids and Seals Standard seals (Nitrile) can be used with petroleum,water-glycols, and water-oil emulsion type fluids.

F1 seals (Butyl, EPR) must be used for alkyl phosphate-es-ter base fluids and aircraft type fire-resistant fluids. F1 sealscannot be used with petroleum or phosphate ester-hydrocar-bon blends.

F3 seals (Viton*) can be used with all commonly usedindustrial hydraulic fluids. Viton* is compatible withpetroleum, water-base and synthetic fire-resistant fluids.

*Trademark of Dupont DeNemours Co., Inc.

Fluid TypeSkydrol Yes NoPydraul 10-E Yes NoPydraul 29-E-L-T, 50-E, 65-E, 115-E Yes YesPydraul 230-C, 312-C, & 540-C No YesFyrquel & Fyrlube Yes YesFyrtek No YesHoughto Safe 1000 Series Yes Yes

The following table summarizes the compatibilities of themost common phosphate ester fluids.

F3F1

C. Piping and Tubing 1. All pipes and tubing must be thoroughly cleaned

before installation. Recommended cleaning methods aresandblasting, wire brushing and pickling. Refer to instructionsheet 1221-S for pickling instructions.

2. To minimize flow resistance and the possibility ofexternal leakage, use only the necessary fittings and con-nections required for proper installation.

3. The number of bends in tubing should be kept to aminimum to prevent excessive turbulence and friction of fluidflow. Tubing must not be bent too sharply. The recom-mended radius for tube bends is three times the insidediameter.

D. Hydraulic Fluid RecommendationsHydraulic fluid within the system performs the dual functionof lubrication and transmission of power. To insure properlubrication, system life, and component reliability, fluidselection should be made carefully with the assistance of areputable supplier. Fluid selection should be acceptable foruse with all valves, motors and pumps within the system.Data sheets for fluid selection are available from your localSales or Engineering representative to order data sheetI-286-S.

The fluid recommendations noted in the data sheet arebased on our experience in industry as a hydrauliccomponent supplier. Where special considerations indicate aneed to depart from these recommendations, see your salesrepresentative.

E. Cleanliness To insure your hydraulic system is clean, perform thefollowing steps:

1. Clean (flush) the entire system to remove paint, metalchips, welding shot, etc.

2. Filter each oil change to prevent introduction ofcontaminants.

3. Provide continuous oil filtration to remove sludge,products of wear and corrosion generated during the life ofthe system.

4. Provide protection to all areas that can introduceairborne contaminants into the system.

5. Perform regular servicing procedures of filters,breathers, and reservoirs.

F. Overload Protection A relief valve must be installed in the system as close to thepump as possible. The relief valve limits pressure in thesystem to a prescribed maximum. The setting of the reliefvalve depends on the work requirements of the system.

25

Section VII – Service, Inspection & Maintenance

A. Service Tools No special tools are required to service this valve series.

B. Inspection Periodic inspection of the fluid condition and tube or pipingconnections can save time consuming breakdowns andunnecessary parts replacement. The following should bechecked regularly.

1. All hydraulic connections must be kept tight. A looseconnection in a pressure line will permit the fluid to leak out.If the fluid level becomes so low as to uncover the inlet pipeopening in the reservoir, extensive damage to the systemcan result. Loose connections also permit air to be drawninto the system resulting in noisy and/or erratic operation.

2. Clean fluid is the best insurance for long service life.Therefore, check the reservoir periodically for long servicelife. Therefore, check the reservoir periodically for dirt andother contaminants. If the fluid becomes contaminated, flushthe entire system and add new fluid.

3. Filter elements should also be checked periodicallyfor dirt and other contaminants. If the fluid becomes contami-nated, flush the entire system and add new fluid.

4. Air bubbles in the reservoir can ruin the valve andother components. If bubbles are seen, locate the source ofair and seal the leak.

C. Adding Fluid to the System When hydraulic fluid is added to replenish the system, pour itthough a fine wire screen (200 mesh or finer). Whenapplicable, pump the fluid through a 10 micron filter. DO NOTuse a cloth to strain the fluid or lint may enter the system.

D. Adjustments No periodic adjustments are required other than normalsystem maintenance.

E. Replacement Parts Reliable operation throughout the specified operating rangeis assured only if genuine Vickers parts are used. Sophisti-cated design processes and material are used in themanufacture of our parts. Substitutions may result in earlyfailure. Part numbers are shown in the parts and servicedrawings listed in Table 1.

F. Product Life The service life of this product is dependent upon environ-ment, duty cycle, operating parameters and systemcleanliness. Since these parameters vary from application toapplication, the ultimate user must determine and establishthe periodic maintenance required to maximize life anddetect potential component failure.

G. Troubleshooting Table 5 lists the common difficulties experienced withdirectional valves and systems. It also indicates the probablecauses and remedies for each of the troubles listed.

Always remember that many apparent failures may actuallybe the failure of other parts of the system. The cause ofimproper operation is best diagnosed with adequate testingequipment and a thorough understanding of the completehydraulic system.

Trouble Possible Cause Remedy

Valve spool fails to move Dirt in system

Solenoids inoperative

Improper assembly

Improper installation connections

Disassemble, clean and flush

Check electrical source and solenoids

Check proper assembly. Refer to ap-propriate figure and assembly procedure

Check installation drawings

Valve produces undesirable response Improper valve assemblyImproper installation connections

Solenoid wiring reversed

Check parts drawing and installationdrawing for proper assembly and instal-lation connections

Reverse connections to the solenoids

Table 5. Trouble Shooting Chart

26

Section VIII – Overhaul

WARNING

Before breaking any circuit connections, be certainthe electrical power is off and all branches of thecircuit are relieved of trapped pressure. Lower allvertical cylinders. Discharge or isolate accumula-tors. Block any load whose movement could causeinjury to personnel or damage to the equipment.

A. Unit Removal Refer to Figure 15.

1. Thoroughly clean the exterior of the valve and thearea around the valve to prevent contamination of thesystem during removal.

2. Remove the valve from its subplate or mounting padas follows:

a. If the valve is equipped with the insta-plug feature,loosen the two slotted screws and unplug the electricalwiring from the pilot section.

b. If the valve has an air operated pilot section, turnoff air supply and disconnect the pressure lines from theconnection plate.

CAUTION

In the following step make sure electrical power isoff, then disconnect the solenoid wiring. Label eachwire to provide assembly information.

c. If the valve has standard electrically operatedsolenoids, remove the four nameplate screw (1) on top of thepilot section. Move nameplate (2) and gasket (3) aside toexpose interior of the wire cavity. Disconnect solenoid wiring.

d. Loosen the six mounting screws that hold themain stage section to the mounting pad. Be ready to catchthe fluid retained inside the lines and valve.

e. Remove the valve from the mounting pad and setit on a clean work bench. Use a chain lift when necessary.

27

Figure 15. Main Stage Section with Check Valve DG5S4-10*-****-53

1 Screw 42 Nameplate (Pilot Valve 13 Gasket 14 Screw 45 O-Ring 56 Body (Main Section) 17 Screw 48 Cover 19 O-Ring 1

10 Spring 111 Washer 112 Screw 413 Cover 114 O-Ring 115 Spring 116 Washer 117 Spool 118 O-Ring 319 O-Ring 220 O-Ring 121 Seat 122 Poppet 123 Spring 124 Sleeve 125 Rest Pin 226 - 48 Plug 13(Consecutive even #’s)27 - 49 O-Ring 13(Consecutive odd #’s)

25

11

1

23

45

6

789

10

1213

14 1516

17

18

19

Item Nomenclature Quantity

2021

22

23

24

26

2728

29

303132

33

3435

36

3738 39

40 41

42

43 4445

46

47

48

49

DG5S4-10*-****-53

28

B. Disassembly General

This manual describes the disassembly sequence of a typicalDG5S4-10*C-W3-53 two-stage directional valve. SeeFigures 15 and 18. Slight variations may be noted on yourmodel depending on the type of accessories and unit design.Figure 15 may be used for all models, except pressurecentered “D” models regardless of the design. Refer to Figure17 for pressure centered “D” models. Figure 18 shows thedisassembly sequence of a DG4S4-016C-W3-*-50 wetarmature pilot valve. If your pilot valve is of a different type,refer to Figures 19, 20 or 21.

C. Pilot Valve Removal Refer to Figure 15.

1. Remove the four attaching screws (4) from the pilotvalve. Remove the pilot valve from the main stage body (6).

2. Remove and discard O-Rings (5) from pilot valvemounting face.

NOTE

The following section (D) pertains to main stagedisassembly. If your unit does not require mainstage disassembly, omit the following section.

D. Main Stage Disassembly Refer to Figure 15.

1. Loosen the four end cover screws (7) from end cover(8). Be ready to catch any oil trapped inside the unit. Re-move the end cover and discard O-Ring (9).

2. Remove spring (10) and washer (11) from main stagespool (17). NOTE: Spring (10) and washer (11) do not existon spring offset “A” or floating type models.

3. Loosen the four screws (12) from end cover (13).Remove the end cover and discard O-Ring (14).

4. If applicable, remove spring (15) and washer (16)form main stage spool (17).

5. Remove main stage spool (17) from body (6).

6. Turn the body (6) on its side and remove O-Rings(18, 19 and 20) from mounting face.

NOTE

The following step (7) pertains to integral checkvalve models only. DO NOT remove check valveparts unless inspection or unit operation indicates acheck valve problem. If check valve removal isnecessary, perform step (7).

7. Select the correct screw listed in Table 6. Obtain apiece of pipe or tubing with an inside diameter that is slightlylarger than outside diameter of seat.

ModelDG5S4-04 .5000-13 UNC-2BDG5S4-06 .5625-18 UNF-2BDG5S4-H06 .875-14 UNF-2BDG5S4-10 1.125-7 UNC-2BDG5S4-H8 .750-16 UNF-2BDG5S4-8 .750-16 UNF-2B

Screw LengthScrew Dia./Thread Type

76.2mm (3”)

Table 6. Screw Tabulation for Seat (21) Removal

Also obtain a flat washer. Remove seat (21), Figure 15, perinstructions noted in Figure 16. Remove poppet (22) andspring (23). DO NOT remove sleeve (24).

Screw

Figure 16. Check Valve Seat Removal

Tubing

Washer

Seat (21)(Figure

15)

NOTE:Thread seat (21)then place tubingand washer overseat area as shown.Thread the screwinto seat (21). Tighten the screw toremove seat.

8. If necessary, remove rest pins (25) with vise grippliers.

9. Remove SAE straight thread construction plugs andO-Rings (26 through 49) from body (6). DO NOT removeconstruction plugs if your unit is equipped with the pipe plugvariety (50 and 51 design models).

NOTE

DO NOT remove the internal plugs of body unlessinspection reveals a problem.

E. Pilot Valve Disassembly Refer to Figure 18.

NOTE

The following steps (1 through 9) describe thedisassembly sequence of a DG4S4-01**-W3*-50wet armature pilot valve. If your pilot valve is of adifferent type, refer to figures 19, 20, or 21 andfollow the item number sequence for disassembly.

1. Remove the two screws (1) from solenoid coil (2) andremove the coil. Remove and discard gasket (3).

2. Remove and discard O-Ring (4) from exposed coretube S/A (7).

3. Remove the two screws (5) from flange (6). Thenremove the flange and core tube S/A from body (38). Re-move and discard O-Ring (8) from core tube S/A.

4. Remove push pin (9), pole face (10), armature (11)and manual plunger (12) from core tube (7). Remove anddiscard O-Ring (13) from manual plunger (12).

29

Figure 17. Main Stage Section, Pressure Centered “D” Model (DG5S4-10*D-W(3)-*-53

1 Pilot Valve 12 Screws 43 O-Rings 54 Body 15 Plug 16 O-Ring 17 Screw 48 Cover 19 O-Ring 1

10 O-Ring 111 Spring 112 Sleeve 113 Piston 114 Spool 115 Screw 416 Cover 117 O-Ring 118 Spring 119 Washer 120 - 45 Plugs & O-Rings 13 each46 O-Ring 447 O-Ring 148 O-Ring 149 O-Ring 150 Rest Pin 2

2511

1

2

3

4

56

789

1012 13

14

151617

1819

Item Nomenclature Quantity

20212223

24

26

27

28

293031

32 33 34 35

3637

38

39

40

41

42

43

4445

4647

4849

DG5S4-10*D-W(3)-*-53

50

30

Figure 18. Wet Armature, Pilot Valve DG4S4-01-**W3-51

1 Screw 4 A, B, C, N2 Coil S/A 1 A, B, C, N3 Gasket 1 A, B, C, N4 ∅ O-Ring 1 A, B, C, N5 Screw 2 A, B, C, N6 Flange 1 A, B, C, N7 ∅ Core Tube 1 A, B, C, N8 ∅ O-Ring 1 A, B, C, N9 ∅ Push Pin 1 A, B, C, N

10 ∅ Pole Face 1 A, B, C, N11 ∅ Armature 1 A, B, C, N12 ∅ Manual Plunger 1 A, B, C, N13 ∅ O-Ring 1 A, B, C, N14 Spring 1 B, C, N15 Spacer 1 C

25

11

12

3

4

56

78

910

1213

14

15

16

17

18

19

Item Nomenclature Quantity Model SourceCode

202122

2324

2627

2829

3031

32

33

3435

3637

38

39

DG4S4-01-**W3-51

15a

19a18a

17a

15a Detent S/A 1 N16 Washer 1 B, C17 Screw 4 C, N17a Screw 4 A, B18 Coil S/A 1 C, N18a Cover 1 A, B19 Gasket 1 C, N19a O-Ring 1 A, B20 Screw 2 C, N21 O-Ring 1 C, N22 Flange 1 C, N23 O-Ring 1 C, N24 Core Tube 1 C, N25 Push Pin 1 C, N26∅ Pole Face 1 C, N27∅ Armature 1 C, N28∅ Manual Plunger 1 C, N29∅ O-Ring 1 C, N30 Spring 1 A, B, C31 Spacer 1 B, C, N32 Washer 1 B, C33 Spool 1 A, B, C, N34 Plug 1 A, B, C, N35 O-Ring 1 A, B, C, N36 Plug 1 A, B, C, N37 O-Ring 1 A, B, C, N38 Body 1 A, B, C, N39 O-Ring 5 A, B, C, N

Item Nomenclature Quantity Model SourceCode

Model Source CodeDG4S4-01-**A-50 ADG4S4-01-**B-50 BDG4S4-01-**C-50 CDG4S4-01-**N-51 N

NOTE:

∅ Included in serviceable core tube S/A

31

Figure 19. DG4S4-01-50, DC, Air Gap & Oil Immersed Type Pilot Valves

1 Nameplate 12 Gasket 13 Screw 44 O-Ring 5

5A DC Solenoid Assembly 2(offset “A” units) DC Solenoid Assembly 1

5B AC Solenoid Assembly 2(offset “A” units) AC Solenoid Assembly 1

5C Oil Immersed Solenoid Assy. 2(offset “A” units) Oil Immersed Solenoid Assy. 1

6 Screw 47 Cover 18 Snap Ring 19 Guide 1

10 O-Rings (Guide) 111 Limiter 212 Spring 113 Snap Ring 114 Guide 115 O-Ring 116 O-Ring 117 Washer (Seal Retainer) 118 Spring 119 Spacer 120 Washer (Spring Centering) 121 Snap Ring 122 Guide 123 O-Ring 124 O-Ring 125 Washer (Seal Retainer) 126 Detent Assembly 127 Spring 128 Spacer 129 Washer (Spring Centering) 130 Spool 131 Push Pin 232 Body & Plug 1

25

11

4

5c

678910

12

131416171819

Item Nomenclature Quantity

20

21 22 23 2426 27

28 293031

32

DG4S4-01-50

15

31

5b

5a

DG4S4-01-C/N-**-50

1110

32

24

Figure 20. DG4V-3*W3-40 Pilot Valve

DG4V-3-**-M-40

25

11

1

2

3

4

5

6

7

8

9

1012

13

1415

1617

1819

2021

2223

26

2728

2930

31

32 3334

35 36

“C” or “N” Models

“A”, “B” or “F” Models

1 Screw 4 A, B, C, F, N2 Carrier 1 A, B, C, F, N3 Screw 1 A, B, C, F, N4 Gasket/Retainer 1 A, B, C, F, N5 Screw 2 A, B, C, F, N6 Screw 1 A, B, C, F, N7 Terminal Box 1 A, B, C, F, N8 Gasket 1 A, B, C, F, N9 Body 1 A, B, C, F, N

10 End Cap 1 A, B, C, F, N11 O-Ring 1 A, B, C, F, N12 Coil S/A 1 A, B, C, F, N13 O-Ring 1 A, B, C, F, N14 Core Tube S/A 1 A, B, C, F, N15 O-Ring 1 A, B, C, F, N16 Push Pin 1 A, B, C, F, N17 Spring 1 A, B, C, N18 Washer 1 C, F

Item Nomenclature Quantity Model SourceCode

19 Detent S/A 1 N20 Washer 1 A21 Spool 1 A, B, C, F, N22 End Cap 1 C, N23 O-Ring 1 C, N24 Coil S/A 1 C, N25 O-Ring 1 C, N26 Core Tube S/A 1 C, N27 O-Ring 1 C, N28 Push Pin 1 C, N29 Spring 1 A, B, C, F, N30 Washer 1 B, C, F31 Washer 1 F32 Washer 1 N33 End Cap 1 A, B, F34 O-Ring 1 A, B, F35 O-Ring 1 A, B, C, F, N36 Pin 1 A, B, C, F, N

Item Nomenclature Quantity Model SourceCode

Model Source CodeDG4V-3-**A-40 ADG4V-3-**B-40 BDG4V-3-**C-40 CDG4V-3-**F-40 FDG4V-3-**N-40 N

NOTE:

33

Figure 21. DG18V-3-C-40 Air Operated Pilot Valve for DG19S4-**-52 Two-Stage Unit

DG18V-3-C-40

11

12

34

5

6

7

8

9

10

1213

14

1516

17

1 Screw 42 End Cover 23 Manual Plunger 24 O-Ring 25 Plunger 26 Seal 27 Guide 28 O-Ring 29 Pin 2

10 O-Ring 211 Retainer 212 Spring 213 Washer 214 Spool 115 Body 116 Pin 117 O-Ring 4

Item Nomenclature Quantity

34

5. Remove spring (14), spacer (15) and washer (16)from body bore.

NOTE

Some parts may not exist on your valve. Check theomit codes on Figure 18. On “N” type pilot valves,detent SA (16a) replaces washer (16). Remove thedetent S/A (16a) but DO NOT remove retaining ringfrom the detent.

6. If the pilot valve is equipped with two solenoids,remove parts (17 through 25 and 30 through 32) fromopposite end of body (38).

NOTE

Spring (30) and washer (32) do not exist on “N”type pilot valves.

NOTE

The following step (7) pertains to spring offset “A”and spring centered “B” pilot valves only.

7. Remove the four screws (17a) from end cover (18a)and then remove the end cover. Remove and discard O-Ring(19a) from end cover. Remove parts (30 through 32) frombody bore.

NOTE

Spacer (31) and washer (32) do not exist on springoffset “A” models.

8. Remove the pilot spool (33) from body (38).

9. Secure the body and remove plugs (34 and 36) frombody (38). Remove O-Rings (35 and 37) from plugs anddiscard.

F. Cleaning All parts must be thoroughly cleaned and kept clean duringinspection and assembly. The close tolerance of the valvebodies and spools make this requirement critical. Clean allparts with a commercial solvent that is compatible with thesystem fluid. Compressed air may be used to clean thevalve, but it must be filtered to remove water and contamina-tion. Clean compressed air is particularly useful for cleaningspool orifices, body passages and drying parts.

NOTE

If the spool shows and indication of damage due tocontamination, drain the fluid from the system.,flush all lines and clean the reservoir. New filterelements should be installed and new fluid shouldbe added to the reservoir.

G. Inspection, Repair andReplacement

1. Check that all internal passages are clean and freefrom obstruction. Examine all mating surfaces for nicks andburrs. Minor nicks and burrs can be removed with crocuscloth or an India stone.

CAUTION

DO NOT stone the edges of spool sealing lands. Re-move minor burrs with #500 grit paper. Use the papervery lightly on the outer diameter of each spool.

2. Inspect all screws for evidence of damaged threads.If threads are damaged, replace the screws.

3. Inspect all springs for distortion or wear. The ends ofthe springs shall be square and parallel to each other.Replace springs that are damaged or distorted.

4. Check push pins, pole faces, washers and manualplungers for burrs, cracks or mushrooming. Replace all partsthat show evidence of wear.

5. Visually inspect the internal coring (bore) of eachbody for heavy scratches or erosion across the spool landsealing areas. If such evidence is found, replace the valve. Ifthe body bore passes inspection, check bore to spoolclearance as follows:

a. Lubricate spools and body bores with cleansystem fluid. Make sure the parts are clean.

b. Insert the spool into its body bore. Rotate the spool360� while moving it back and forth. Observe the following:

If the spool does not move freely, the spool is sticking insidethe body bore. Remove the spool and recheck the spool andbody bore for scratches and/or burrs. Remove any minorscratches or burrs with India stone or crocus cloth. Repeatsteps (a) and (b). (NOTE: An alternate test is to turn thebody on end and allow gravity to pull the spool from the bodyinto your hand. If the spool does not move under theinfluence of gravity, the spool is sticking inside the bodybore.) If the spool binding persists, replace the valve.

Check the feel of the spool. If side movement of the spoolcan be felt within the body bore, the body/spool clearancesare excessive. A new spool and body have a select fit ofapproximately 0.0002-0.0003 inch. Body/spool clearances inexcess of this value may still work satisfactory in yoursystem; however, limitations are dependant on how muchleakage your system can tolerate. Normally, excessivebody/spool clearances dictate replacing the entire valve.

NOTE

If a new spool is installed into a new or used body, breakthe feathered edges of the spool balancing grooveswith a three or four cornered India stone. See Figure22. Lightly polish the spool with #500 grit paper. Washthe spool in clean solvent. Repeat steps (a) and (b).

NOTE

The following step (6) pertains to detented “N” pilotvalves only.

6. Check the detent by moving the push pin through thedetent. A steady frictional force should be observed. If thedetent force is weak (less than 1 lb.), replace the detentsubassembly. The detent should be assembled on thepolished end of the spool (DG4S4-01*N-W-51) models.

7. Perform a continuity test on each solenoid coil S/A.Resistance values will vary with the voltage rating of the coil.Refer to Table 7. This test is superficial, but a more rigoroustest requires special equipment. If the coil seems to beburned or extreme heat is encountered during operation, thecoil may be shorted. Make sure the correct voltage is beingapplied to the coil.

35

Land BalancingGrooves

Figure 22. Spool Balancing Grooves

Voltage6 DC 1.5 Ohms12 DC 5 Ohms24 DC 24 Ohms48 DC 80 Ohms115 DC 480 Ohms230 DC 1800 Ohms115 AC(60 Hz)230 AC(60 Hz)460 AC(60 Hz)

Coil Resistance

Table 7. Coil Resistance

13 Ohms

50 Ohms

204 Ohms

H. Assembly Before assembly, obtain the correct seal kit as noted in theparts drawing. Lubricate all O-Rings and internal parts withclean system fluid to provide initial lubrication and facilitateassembly.

Check the model code to determine correct assembly ofunits. If a L.H. suffix appears in the model code, the pilotvalve solenoid is assembled left hand. In such cases, all pilotvalve parts are reversed except the body and spool.

Assembly will be in reverse of the disassembly sequenceshown in Figures 15 and 18 unless otherwise indicated.

1. Assembly of Main Stage Section

Refer to Figure 15.

a. Install O-Rings on construction plugs. Lubricateplug threads and install plugs into body (6). Torque plugs tovalue noted in parts drawing. Refer to Table 1.

b. Tap new rest pin(s) (25) into place if removedduring disassembly.

NOTE

The following step (c) pertains to integral checkvalve models only.

c. Place spring (23) into poppet (22) and then installthe poppet into pressure port (P) cavity as shown. Obtain asuitable push rod and press seat (21) (large diameter faceup) into pressure port (P) cavity. Use an arbor press for thisoperation. Install O-Ring (20) into pressure port mountinggroove.

d. Install O-Rings (19) into “X” and “Y” port mountinggrooves.

e. Install O-Rings (18) into port mounting grooves“A”, “B” and “T”.

f. Lubricate spool lands with clean system fluid andthen carefully install spool (17) into main body bore. Makesure the spool moves freely inside the body bore and isoriented properly. (See parts drawing.)

g. Install washer (16) and spring (15) on end of spool(17). (NOTE: Spring (15) and washer (16) do not exist onspring offset “A” or “floating” type models.)

h. Install O-Ring (14) into cover (13) as shown.

i. Fasten cover (13) to end of body (6) with fourscrews (12). Torque the screws (12) to value note in partsdrawing. Make sure cover is oriented properly (in line withbody contours).

j. If applicable, install washer (11) and spring (10) onopposite end of spool. (NOTE: Spring (10) and washer (11)do not exist on “A” or “floating” type models).

k. Install O-Ring (9) into cover (8).

l. Fasten cover (8) to end of body with four screws(7). Torque screws to value shown in parts drawing.

2. Assembly of Pilot Valve Section

Refer to Figure 18.

a. Spring centered “B” and “C” models:

1. Install O-Ring (35 and 37) on plugs (34 and 36).Lubricate plug threads and install into body (38) as shown.Torque plugs to the value shown in part drawing. See Table 1.

2. Lubricate pilot spool (33), then carefully installspool into the body bore.

3. Assemble washer (32) on end of spool (33) withsharp break edge toward outside of body.

4. Install spacer (31) on end of pilot spool withspacer counterbore facing push pin (25).

5. Install spring (30) into body bore.

NOTE

The following steps (6 through 8) pertain to springcentered “B” models only.

6. Assemble O-Ring (19a) on cover (18a), thenassemble cover to valve body (38) with screws (17a). Torquescrews to the value shown in parts drawing.

7. Install washer (16) on end of valve spool withsharp break edge toward outside of valve.

8. Install spring (14) into body cavity over washer.

NOTE

The following steps (9 thorough 16) pertain tospring centered “C” models only. If your valve isequipped with serviceable core tub S/A (W3),perform step (9). Omit step (9) if your model hasnonserviceable core tubes (W). Non serviceablecore tubes CANNOT be disassembled.

9. Install O-Ring (29) on manual plunger (28).Lubricate plunger (28) and O-Ring (29) with petroleum jelly.

a. Insert manual plunger (28) into the hole atthe bottom of core tube (24) with the shoulder of the plungeron the inside of the core tube.

36

b. Install armature (27) into core tube asshown. Make sure the armature fits over the manual plungerat the bottom of the tube. Use the correct armature S/A forAC and DC operation. See parts drawing.

c. Install pole face (26) into the core tube ontop of the armature.

d. Insert push pin (25) into pole face hole.Assemble O-Ring (23) into groove of pole face.

10. Assemble flange (22) on core tube (24) withchamfer side facing body (38).

11. Assemble core tube (24) and flange (22) tobody (38) with screws (20). Torque screws to value shown inparts drawing.

12. Install washer (16) on end of spool with sharpbreak edge toward outside of valve.

13. Install spacer (15) with chamfer towardpush pin.

14. Install spring (14) into body (38) overspacer (15).

15. Install O-Ring (21) over core tube (24) andinto its O-Ring groove.

16. Insert two screws (17) through coil S/A (18).Place gasket (19) over the screws and assemble coil overcore tube. Thread coil wires into body cavity. Torque screwsto the value shown in parts drawing.

NOTE

The following steps (17 through 25) pertain to (B &C) spring centered models.

17. Install O-Ring (13) on manual plunger (12).Lubricate with petroleum jelly.

18. Insert manual plunger (12) into hole at thebottom of core tube (7) with the shoulder of the plunger onthe inside of the core tube.

19. Install armature (11) into crore tube as shown.Make sure the armature fits over the manual plunger at thebottom of the core tube. Use correct armature S/A for ACand DC operation. See parts drawing.

20. Install pole face (10) into core tube (7) on topof armature (11).

21. Insert push pin (9) into pole face hole.Assemble O-Ring (8) in groove of pole face.

22. Assemble flange (6) on core tube (7) withchamfer side facing body (38).

23. Assemble core tube (7) and flange (6) againstbody (38) with screws (5). Torque screws to value shown inparts drawing.

24. Install O-Ring (4) over core tube S/A (7) andinto the O-Ring groove.

25. Insert two screws (1) through coil S/A (2).Place gasket (3) over the screws and assemble coil overcore tube. Thread coil wires into body cavity. Torque screwsto the value shown in parts drawing.

b. Spring offset “A” models:

See Figure 18.

NOTE

Observe the model code. If left hand (LH) assemblyis required, reverse all pilot parts except body andspool.

1. Install O-Rings (35 and 37) on plugs (34 and36). Lubricate plug threads and install into body (38) asshown. Torque the plugs to valve shown in parts drawing.

2. Lubricate the pilot spool (33), then carefullyinstall spool into the body bore. Orient small end of spooltoward cover (18a).

3. Install spring (30) into body bore.

4. Assemble O-Ring (19a) into groove of cover(18a). Lubricate O-Ring with petroleum jelly and place coveragainst end of valve body (38). Thread screws (17a) throughcover into body and torque to the value shown in partsdrawing.

5. Assemble and install solenoid S/A parts andcoil S/A. Perform steps a.17. through a.25.

c. Detent “N” models:

Refer to Figure 18.

1. Install O-Rings (35 and 37) on plugs (34 and36). Lubricate plug threads and install plugs into body (38)as shown. Torque the plugs to valve shown in parts drawing.

2. Lubricate the pilot spool (33), then carefullyinstall spool (33) into the body bore. Polished end of spoolmust face detent (15a) end of valve.

3. Install spring (14) and detent (15a) over end ofvalve spool.

4. Assemble spacer (31) over the end of spool(33) with chamfered end of spacer facing push pin (25).

5. Assemble core tubes and coils to ends of thevalve. Perform steps a.9 through a.11 and a.15 through a.25.

3. Assembly of Pilot Valve to Main Stage Section:

Refer to Figure 15.

a. Apply a heavy amount of petroleum jelly toO-Rings (5) and pilot valve mounting face grooves. InstallO-Rings into pilot valve.

b. Assemble a lock washer on each of the fourscrews (4). Lubricate screw threads and insert screwsthrough pilot valve body.

c. Line up the port holes and screw holes. Make sureO-Rings do not slip out of position. Attach pilot valve to mainstage section and thread screws into valve hand tight.Torque screws evenly to value shown in parts drawing. DONOT OVER TORQUE.

d. Mount the two stage valve on a manifold orsubplate. Refer to installation drawing, Table 1, forinstructions and bolt kit number.

e. Connect electrical power to solenoid wire leads. Ifan air operated pilot valve is used, connect the air lines tothe connection plate.

f. Install nameplate (2) and gasket (3) on pilot valvebody if previously removed.

g. Insert four screws through nameplate (2) andgasket (3). Secure nameplate to the pilot valve body.

37

Section IX – Internal Body Passages & Plug Locations

Two stage directional valves can be converted to differentoperational modes, i.e., internal/external, pilot pressure ordrain, fast response, etc. To accomplish this, internal plugsmust be removed or added within the main stage bodypassages.

Table 8 is a list of basic models with the incorporatedoperational mode changes. Each model is referenced to aparticular figure. The figures illustrate internal passages andplug locations.

Operational Mode Change(Reference model code, Table 2)

* - StandardX - Fast response optionE - External pilot pressure

CAUTION

DO NOT change internal plugs within mainstage body unless power is off and systempressure is relieved.

K/R/S - Integral check valveT - Internal pilot drain

Basic Model DescriptionDG5S4-04**-*-40DG5S4-04**X-*-40DG5S4-04**-E-*-40DG5S4-04**X-E-*-40DG5S4-04**-K/R/S-*-40DG5S4-04**-E-K/R/S-*-40DG5S4-04**-X-K/R/S-*-40DG5S4-04**-X-E-K/R/S-*-40DG5S4-04**-T-*-40DG5S4-06**-*-51DG5S4-06**X-*-51DG5S4-06**-E-*-51DG5S4-06**X-E-51DG5S4-06**-K/R-*-51DG5S4-06**-E-K/R-*-51DG5S4-06**X-K/R-*-51DG5S4-06**X-E-K/R-*-51DG5S4-06**-T-*-51DG5S4-H06**-*-51DG5S4-H06**X-*-51DG5S4-H06**-E-*-51DG5S4-H06**X-E-*-51DG5S4-H06**-K/R/S-*-51DG5S4-H06**-E-K/R/S-*-51DG5S4-H06**X-K/R/S-*-51DG5S4-H06**X-E-K/R/S-*-51

Reference

Table 8. Internal Passages & Plug Tabulation

Figure 23a

Figure 23b

Figure 23c

Figure 24a

Figure 24b

Figure 24c

Figure 25a

Figure 25b

DG5S4-H06**-T-*-51

DG5S4-10**-*-51/53DG5S4-10**X-*-51/53DG5S4-10**-E-*-51/53DG5S4-10**X-E-*-51/53DG5S4-10**-K/R/S-*-51/53DG5S4-10**-E-K/R/S-*-51/53DG5S4-10**X-K/R/S-*-51/53DG5S4-10**X-E-K/R/S-*-51/53DG5S4-10**-T-*-51/53DG5S-(H)8**-*-10/20DG5S-(H)8**X-*-10/20DG5S-(H)8**-E-*-10/20DG5S-(H)8**X-E-*-10/20DG5S-(H)8**-K/R/S-*-10/20DG5S-(H)8**-E-K/R/S-*-10/20DG5S-(H)8**X-K/R/S-*-10/20DG5S-(H)8**X-E-K/R/S-*-10/20DG5S-(H)8**-T-10/20DG5S4-H06*D-51DG5S-8-*D-*-10DG5S4-06*D-*-51DG5S4-10*D-*-51/53

Figure 25c

Figure 26a

Figure 26b

Figure 27a

Figure 27b

Figure 27c

Figure 24a(Internal plug

locations only)

Figure 26c

Basic Model Description Reference

38

Section X – Start-up and Test

A. Start-up Start the system and sequence the unit through allpositions while watching for appropriate movement ofactuators. Improper or erratic movement of the actuatorsmay indicate incorrect assembly of the unit or presence oftrapped air.

B. Test A test stand having regulated flow, temperature control andspecial fixtures is required to fully test the performance ofthe rebuilt unit. Because of this, only the functional testshown in the start-up paragraph is given. If such a teststand is available, test the unit to the requirements set forthin the installation drawings.

Figure 23a. DG5S4-04-X-40 Internal Pressure Passages & Plug Locations

Plug Installation Table

Model “C”Plug

“B”Plug

“A”Plug

DG5S4-04-40DG5S4-04-X-40DG5S4-04-E-40DG5S4-04-X-E-40

Doesnot

Exist

*InOutInIn

OutOut*InOut

* - Denotes Orifice Plug

BPTA

“P” Port

“B” Plug

“C” Plug

“X” Port

39

Figure 23b. DG5S4-04-(K/R/S)-40 Internal Pressure Passages & Plug Locations

Plug Installation Table

Model “C”Plug

“B”Plug

“A”Plug

DG5S4-04-K/R/S-40DG5S4-04-X-K/R/S-40DG5S4-04-E-K/R/S-40DG5S4-04-X-E-K/R/S-40

InInInIn

OutOut*InOut

* - Denotes Orifice Plug

BPTA

“P” Port

“B” Plug

“C” Plug

“X” Port

*InOutInIn

NOTE:

Open Center Spools 0, 4, 8 & 9 cannot function unlessExternal Pilot Pressure “E” or a 50/75 psi Check“R”/“S” is used.

“A” Plug

Figure 23c. DG5S4-04-T-40 Internal Pressure Passages & Plug Locations

BPTA

“T” Plug(Remove for Internal

Drain Models)

“Y” Port

40

Figure 24a. DG5S4-06*-51 or DG5S4-06*-D-52 Internal Pressure Passages & Plug Locations

Plug Installation Table

Model “C”Plug

“B”Plug

“A”Plug

DG5S4-06*-51DG5S4-06*-E-51DG5S4-06*-X-51DG5S4-06*-X-E-51

*InIn

OutIn

OutIn

Out

* - Denotes Orifice Plug

B

P

TA

“B” Plug

“C” Plug

“X” Port

Out

T

Figure 24b. DG5S4-06*-(K/R)-51 Internal Pressure Passages & Plug Locations

Plug Installation Table

Model “C”Plug

“B”Plug

“A”Plug

DG5S4-06*-KR-51DG5S4-06*-E-KR-51DG5S4-06*-X-KR-51DG5S4-06*-X-E-KR-51

*InIn

OutIn

Out*In

* - Denotes Orifice Plug

B

P

TA

“B” Plug

“C” Plug

“X” Port

In

T

“A” Plug

IntegralCheck Valve

Out

41

Figure 24c. DG5S4-06-T-51 Internal Drain Passages & Plug Locations

B

P

TA

“T” Plug(Remove for Internal Drain Models)

“Y” Port

T

Drain Port Internal Coring

Figure 25a. DG5S4-H06-*-51 Internal Pressure Passages & Plug Locations

Plug Installation Table

Model “C”Plug

“B”Plug

“A”Plug

DG5S4-H06*C-51DG5S4-H06*C-E-51DG5S4-H06*C-X-51DG5S4-H06*C-X-E-51

*InIn

OutIn

Out*In

Out

* - Denotes Orifice Plug

B

P

TA

“B” Plug

“X” Port

Doesnot

Exist

T

“C” Plug

42

Figure 25b. DG5S4-H06-(K/R/S)-51 Internal Pressure Passages & Plug Locations

Plug Installation Table

Model “C”Plug

“B”Plug

“A”Plug

DG5S4-H06*C-KRS-51DG5S4-H06*C-E-KRS-51DG5S4-H06*C-X-KRS-51DG5S4-H06*C-X-E-KRS-51

*InIn

OutIn

Out*In

* - Denotes Orifice Plug

B

P

TA

T

“A” Plug

Check ValvePressure

Pickup Line

InOut

“B” Plug

“C” Plug

GaugeConnection

Figure 25c. DG5S4-H06-T-51 Internal Drain Passages & Plug Locations

B

PT

A

“T” Plug (Remove for Internal Pilot Drain Models)

“Y” Drain

Drain Port Internal Coring

T

43

Figure 26a. DG5S4-10**-53/54 Internal Pressure Passages & Plug Locations

Plug Installation Table

Model “C”Plug

“B”Plug

“A”Plug

DG5S4-10**-53DG5S4-10**-E-53DG5S4-10**-X-53DG5S4-10**-X-E-53

*InIn

OutIn

Out*In

* - Denotes Orifice Plug

B

P

TA

T

“C” Plug

Doesnot

ExistOut

“B” Plug

“X” Port

Figure 26b. DG5S4-10**-(K/R/S)-53 Internal Pressure Passages & Plug Locations

Plug Installation Table

Model “C”Plug

“B”Plug

“A”Plug

DG5S4-10**-K/R/S-53DG5S4-10**-E-K/R/S-53DG5S4-10**-X-K/R/S-53DG5S4-10**-X-E-K/R/S-53

*InIn

OutIn

Out*In

* - Denotes Orifice Plug

B

P

TA

T

“C” Plug

In

Out

“B” Plug

“X” Port

Integral Check Valve

“A” Plug

44

Figure 26c. DG5S4-10**-T-53 Internal Drain Passages & Plug Location

B

P

TA

“T” Plug (Remove for Internal Drain Models)

TDrain Port Internal Coring

“Y” Port

Figure 27a. DG5S-8-*-10 or DG5S-H8-*-20 Internal Pressure Passages & Plug Locations

B

P

A T

“P” Port

Plug Installation Table

Model “C”Plug

“B”Plug

“A”Plug

DG5S-8-**-10DG5S-8-**-E-10DG5S-8-**-X-10DG5S-8-**-X-E-10

*InIn

OutIn

Out*In

* - Denotes Orifice Plug

Doesnot

ExistOut

“C” Plug

“B” Plug

45

Figure 27b. DG5S-8-** (K/R/S)-10 or DG5S-H8-**(K/R/S)-20 Internal Pressure Passages & Plug Locations

B

P

A T

“X” Port

Plug Installation Table

Model “C”Plug

“B”Plug

“A”Plug

DG5S-8-**-KRS10DG5S-8-**-E-KRS-10DG5S-8-**-X-KRS-10DG5S-8-**-X-E-KRS-10

*InIn

OutIn

Out*In

* - Denotes Orifice Plug

Doesnot

Exist Out

“C” Plug

Check Valve

“A” Plug

Figure 27c. DG5S8-**-10 or DG5S-H8-**-20 Internal Drain Passages & Plug Locations

B

P

AT

“Y” Port

“T” Plug (Remove for Internal Drain Models)

DG5S8-10 (with or w/o check valve) orDG5SH8-20 (with or w/o check valve)Internal Drain Passages & Plug Locations